Advanced Gun Barrel Technologies Program Status

Transcription

1 Advanced Gun Barrel Technologies Program Status Dr. Amir Chaboki United Defense NDA Guns -Ammunition - Rockets - Missiles Conference 28 April 2005 FNC227.ppt - Page 1

2 Large Caliber Naval Guns MK 45 / Mod. 2 Bore: 5-inch (127mm) Length: 54cal, 22.5 ft (6.9m) Operating Pressure: 55 kpsi (380 MPa) Range: 13 Nmi Volume of Fire: rnds/min (20 round ready service) Barrel Life: 8000 rnds Thermal Mgmt: Air Cooling Mark 67 charge with various projectiles MK 45 / Mod. 4 Bore: 5-inch (127mm) Length: 62cal, 25.8 ft (7.9m) Operating Pressure: 63 kpsi (435 MPa) Range: 63 Nmi Volume of Fire: 10 rnds/min Barrel Life: 1,500 rnds Thermal Mgmt: Air Cooling ERGM Projectile/Propelling Charge ncreased performance levels result in barrel life becoming a logistics cost driver FNC227.ppt - Page 2 Advanced Gun System (AGS)* Bore: 155mm (6.1 in) Length: 62cal, 31.5 ft (9.6m) Operating Pressure: 53 kpsi (365 MPa) Range: XX Nmi Volume of Fire: 10 rnds/min Continuous Barrel Life: 3,000 rnds (Est.) Thermal Mgmt: Liquid Cooling Long Range Land Attack Projectile/Propelling Charge *Currently Under Development

3 Limitations of Current Barrel Technology The trend of gun performance requirements has been for increased range and rate of fire for centuries Wear and thermal management limit system performance Highest energy propelling charge and advanced projectile solutions are precluded by barrel limitations mproving wear, erosion or thermal management yields increased system performance FRE SUPPORT 25 NM 41 NM 63 NM 100 NM 200+ NM NACO M6 60 Pressure (ksi) Acceptable Pressures, Temperatures and Erosion Risk Area due to accelerated erosion Erosion Limit Barrel Elastic Limit Barrel Fatigue Limit 35 Risk Area due to rapidly degrading, and increasingly uncertain material properties nner Bore Temperature (F) ncreasing Performance Trend EX-99 Barrel Design Space Limits Elastic strength Fatigue strength Max bore temperature Wear and erosion FNC227.ppt - Page 3

4 Advanced Gun Barrel Technologies Future Naval Capabilities Program Objectives - dentify & develop Gun Barrel Technologies that enable upgrades to existing barrel capabilities for Naval gun propulsion missions ncreased Gun Barrel Erosion & Fatigue Life mproved Gun Barrel Thermal and Ballistic Performance Reduced Life Cycle Cost Payoffs - ncreased Gun System Availability - mproved Ballistic Capability (Higher KE for increased range) - Lower Life Cycle Cost Transition - Develop/Demonstrate mproved Barrel Life and Ballistic performance over AGS Baseline for Transition into Future DD(X) Flights FNC227.ppt - Page 4

5 Advanced Gun Barrel Technologies Plan Develop Two Advanced Barrel Technologies Concurrently 1- Refractory / Steel Barrel : Focus on the technologies providing longer barrel erosion and fatigue life. - Develop and apply alternate coating / liner material and processing to the existing Chromium plating. 2- Composite Barrel : Develop Composite gun Barrel for improved thermal management and wider design space for enhanced ballistic performance for current and future gun barrels - Technologies such as Metal Matrix Composites that provide more flexibility in achieving desired material properties in radial and axial directions in the barrel Each technology path will provide increased barrel life and if both successful, will be combined for substantial barrel life improvement FNC227.ppt - Page 5

6 Advanced Gun Barrel Technologies FNC Refractory Lined / Coated Steel Barrel Technical Approach FY03 FY04 FY05 FY06 FY07 TECHNOLOGY SELECTON Trades / Screening Tests MEDUM CALBER COMPETTON AGS 155-mm PROTOTYPE DESGN & FAB AGS GUN DEMONSTRATON Magnetron Sputtering Solid Free Form Fab Explosive Cladding Extended Barrel Life Competition in Small Caliber Barrel (76-mm) Downselect Technology for AGS Application Develop AGS Design Fab AGS 155-mm Barrel Barrel Proof Out AGS Gun Demonstration Qualification / Transition Others Potential Liner / Coating Technology nsertion Point Advanced Composite Barrel FY03 FY04 FY05 FY06 FY07 NTERFACE TECHNOLOGY System Level/Concept Trades COMPONENT DESGN/VALDATON COMPOSTE GUN BARREL DESGN FABRCATE COMPOSTE BARREL Final Design Downselect DEMONSTRATON TESTNG Thermal Transfer Load Transfer Chemical Compatibility Component Modeling, Design, & Fabrication Component Test & Validation Develop FGM Design Model & Test/Validate a Full-Bore Short Section Prepare Facilities Fabricate AGS Prototype Barrel AGS Composite Barrel Demonstration FNC227.ppt - Page 6

7 Development Approach Refractory Barrel Technology Technology Assessment Subscale Competition/Demo Electroless Nickel-Boron Ta Sputtering Explosive Cladding Screening Evaluations CED Explosive Clad Barrel Test EPVD Barrel Test Chrome Plated Barrel Test } 76mm Gun Tests Vendor Down select EPVD Free Form Fabrication Develop 155mm Refractory Barrel Design Fabricate 155mm Refractory Barrel Proof Test 155mm Refractory Barrel FNC227.ppt - Page 7 Demo Test 155mm Refractory Barrel

8 Advanced Gun Barrel Technology Transition Criteria 1 - Compliance with AGS nterface Control Document (CD) 2 - Equivalent Ballistic Performance to Baseline AGS Barrel 3-50% mprovement in Barrel Life Over Baseline AGS Barrel 4 - Reduced Life Cycle Cost Compared to Baseline AGS Barrel 5 - Production and Gun Fire Testing of Full-scale Prototype FNC227.ppt - Page 8

9 45mm Test Fixture kg kg projectile projectile 45mm/67 45mm/67 caliber caliber smoothbore smoothbore barrel barrel 45mm 45mm Rifled Rifled Test Test nsert nsert liter liter chamber chamber Accurately reproduces the thermal, chemical and mechanical environment of a large caliber gun 50 shot test sequences used to evaluate coating adhesion and integrity Over 700 shots fired to date 45mm gun in place at UDLP test range Provides cost effective means of evaluating coatings for large caliber gun application FNC227.ppt - Page 9

10 Test nsert Test insert used to evaluate the performance of advanced coating materials nsert includes shot start region and first few calibers of projectile travel Thickness sized to provide a strain level similar to the AGS barrel at maximum service pressure conditions for LRLAP nsert does not simulate compressive residual stress from autofrettage in the AGS barrel No twist rifling FNC227.ppt - Page 10

11 Candidate Coating Technologies Electroless Nickel-Boron Sputtering Plasma (onized nert Gas) Explosive Cladding Plasma Power Supply + 300V - Substrate (Gun Tube) COLLSON Ar e e - e - Ar+ e - Magnetic Ta Field Lines, B V Target Power Supply GND Target (Cathode) Catalytic plating process produces extremely uniform coating even on complex geometries Coaxial Energetic Deposition Material is sputtered, from a coaxial target, uniformly over the inside diameter of the barrel Electromagnetically Enhanced Physical Vapor Deposition Tube of cladding material is mechanically bonded with the gun barrel in a collision driven by an explosive detonation Solid Free-Form Fabrication Plasma arc rotates around center conductor and travels along its length depositing material Electrically controlled magnetic fields enhance the plasma environment of the physical vapor Engineered material is created by alloying of powdered and/or wire-fed metals FNC227.ppt - Page 11

12 Candidate Coating Technologies Electroless Nickel-Boron Sputtering Explosive Cladding Plasma (onized ner t Gas) 300V e- + - Substr ate (Gun Tube) Plasma Power Supply COLLSON Ar e- e Ar + e- Magnetic Field Lines, B Ta V Tar get Power Supply Tar get (Cathode) Catalytic plating process produces extremely uniform coating even on complex geometries Coaxial Energetic Deposition Plasma arc rotates around center conductor and travels along its length depositing material GND Material is sputtered, from a coaxial target, uniformly over the inside diameter of the barrel Tube of cladding material is mechanically bonded with the gun barrel in a collision driven by an explosive detonation Electromagnetically Enhanced Physical Vapor Deposition Solid Free-Form Fabrication Electrically controlled magnetic fields enhance the plasma environment of the physical vapor FNC227.ppt - Page 12 Engineered material is created by alloying of powdered and/or wire-fed metals

13 Chrome Plated Baseline Unfired Sample 57 Firings Chrome Plating Heat Affected Zone Heat Check Crack Chrome plating showed very little evidence of wear, visual appearance compared favorably with 155mm gun barrel assets with approximately fifty shots Chrome plated baseline showed damage from heat checking, chemical attack and thermally altered grain structure similar to that characteristic of large caliber gun systems FNC227.ppt - Page 13

14 Explosive Cladding Unfired Sample 50 Firings Refractory metal alloy coating showed minimal effects after 50 firings Heat checks were significantly fewer and smaller than the chrome baseline The substrate appeared unchanged after 50 firings with no heat affected zone nterface between coating and substrate shows evidence of an overly energetic clad FNC227.ppt - Page 14

15 Explosive Cladding Prototype Barrel Assembly For Mk 75 76mm Gun Key areas of development Cladding the complex geometry of the chamber Transitions and overlaps in successively clad layers Quantification of residual stresses resulting from the explosive event Machining operations in the clad alloy Boring Honing Cutting Grinding FNC227.ppt - Page 15

16 Electromagnetically Enhanced Physical Vapor Deposition Unfired Sample 50 Firings Coating applied over thin interlayer showed good adhesion Less than 10% of material removed after 50 firings nterlayer corroded much more rapidly than either refractory metal or steel nterlayer separated from steel at point of highest heat input FNC227.ppt - Page 16

17 EPVD Prototype Barrel Assembly For Mk 75 76mm Gun Key areas of development Application of an adherent coating that does not use an interlayer Application of a uniform coating on a barrel with complex D and OD geometry FNC227.ppt - Page 17

18 Program Status Completed screening candidate technologies based on performance in gun firing tests Selected two for continued development and demonstration in 76mm scale, Explosive Cladding and Electromagnetically Enhanced Physical Vapor Deposition (EPVD) Completed producibility reviews on both technologies incorporating information into preliminary designs for 76mm prototype barrels and identifying key areas of development Currently working to demonstrate successful resolution of all key issues for both technologies FNC227.ppt - Page 18

19 Path Forward Prototype 76mm barrel assemblies scheduled to be complete end of 05 with rapid fire testing conducted early 06 Down-select to single technology for application in full scale 155mm barrel to be built in Demonstration of technology via proof fire testing and rapid fire testing in 155mm in 07 FNC227.ppt - Page 19